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What defects may appear when workpieces have oil contamination or rust on the surface during welding at a robot seam welding workstation?
Nov 09,2026
When a robot seam welding workstation welds fuel tanks, water tanks and similar products, residual oil and rust on the workpiece may change conduction, heat transfer and contact conditions and lead to various seam weld defects.
I. Poor seam fusion with a risk of leakage
1. Oil and the rust layer block current conduction, contact resistance becomes unstable, and lack of fusion and undersized nuggets easily occur.
2. Rust and oil combustion residue remain inside the seam and form slag inclusions, which may weaken seam density.
3. Locally excessive resistance and concentrated heat easily burn through the sheet to form holes, which may cause leakage.
II. More spatter and arcing, damaged seam appearance
1. Oil vaporizes at high temperature and the rust layer breaks down, producing arcing and heavier spatter, with burning and blackening around the seam.
2. Spatter residue falls onto the inner wall and may affect internal cleanliness; residue on the outer wall affects subsequent painting.
3. The seam is formed roughly at arcing spots with poor appearance consistency, increasing the grinding workload.
III. Weld wheel and equipment wear
1. Rust and carbonized residue adhere to the weld wheel surface, causing slag sticking, build-up and wear deformation.
2. Once the seam becomes abnormal, the force and conduction conditions on the weld wheel are inconsistent, increasing dressing and replacement frequency.
3. Impurities enter the welding circuit, affecting stable current output and causing equipment state fluctuation.
IV. The seam area may rust and fail later
1. Heat concentrates at impurities, the seam is blackened and rough, the local sheet is thinned by heat and its strength drops.
2. The welding heat destroys the original anti-rust layer of the sheet, and residual rust impurities in the seam make re-rusting likely later.
3. Where seam density is insufficient, corrosion may accelerate in humid environments and service life is affected.
V. Possible chain defects in continuous welding
1. Oil and rust are unevenly distributed, the resistance differs greatly between seam segments, and defects appear at random positions.
2. Spatter and residue from the previous segment change the sheet surface state and affect the contact of the adjacent segment.
3. Seam defects are hard to find in time, defects accumulate in batch production and rework costs may rise.
Wuxi Haifei Intelligent Equipment Co., Ltd. official website: https://www.haifeiwelder.com/
Wuxi Haifei Intelligent Equipment Co., Ltd. has been dedicated to the research and production of robotic seam welding workstations for 17 years. The company has passed the ISO9001 quality management system certification, the national 3C certification and the CE certification. It is a national high-tech enterprise, a Specialized, Refined, Distinctive and Innovative enterprise of Jiangsu Province, a Specialized, Refined, Distinctive and Innovative enterprise of Wuxi City, and a Gazelle enterprise of the Southern Jiangsu National Independent Innovation Demonstration Zone. If you are interested in our robotic seam welding workstations, please contact us: liuyiyu@jshaifei.com
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Wuxi HAIFEI Intelligent Equipment Co., Ltd.
Wuxi HAIFEI Welding Equipment Co., Ltd.
Add: 28 Shuiyun Road, Yuecheng, Jiangyin, Jiangsu Province, China. (Postal Code: 214404)
Mobile: +86 18915302352
Email: wushijie@jshaifei.com